Steam Generator Segmentation for Superheated Exhaust Recovery
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Solution Overview
Problem
Current steam generation systems are inefficient in converting saturated liquid water to superheated steam using heated gas from combustion engines, particularly in applications like landfill anaerobic digestion and diesel engines, where temperature and power output are critical for effective power generation.
Innovation Solution
A steam generation system comprising a steam generator that utilizes a stream of heated gas to produce superheated steam through a series of heat exchanger units and a superheater, with a circulatory loop including a buffer tank, pump, and condenser, optimized for efficient energy transfer and temperature elevation from saturated liquid to superheated steam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional heat exchanger systems are used to generate superheated steam from combustion exhaust gas, then steam generation is achieved, but energy efficiency is poor and temperature control is insufficient
Solution Approach 1:
The steam generation system is divided into three distinct segments: an economizer section for preheating feedwater, an evaporator section for generating saturated steam, and a superheater section for producing superheated steam. Each segment is optimized for its specific function, allowing efficient energy utilization across the entire system while achieving the required temperature range of 300-400°C.
Solution Approach 2:
The system utilizes parameter changes by varying the temperature and pressure conditions at different stages of steam generation. The economizer operates at lower temperatures for preheating, the evaporator operates at saturation conditions, and the superheater operates at elevated temperatures (300-400°C) and pressures (up to 60 bar), optimizing energy transfer at each stage.
2Productivity
If simple heat exchanger designs are used, then device complexity is reduced, but heat transfer efficiency and power generation output are insufficient
Solution Approach 1:
The heat exchanger employs a nested tube arrangement where tubes are arranged in bundles with inner tubes containing feedwater and outer tubes carrying combustion exhaust gas. This nested configuration maximizes heat transfer surface area within a compact volume, enabling efficient power generation (0.2-3.2 MW) while maintaining manageable structural complexity.
Solution Approach 2:
The system transitions from two-dimensional heat exchange surfaces to three-dimensional tube bundles with multiple passes and interconnected chambers. This dimensional expansion provides extensive heat transfer surface area and multiple flow paths, enhancing power generation capacity while organizing complexity into a structured three-dimensional arrangement.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively generates superheated steam from saturated liquid water, achieving temperatures of 300°C to 400°C and pressures up to 60 bar, enhancing power generation efficiency and output in applications ranging from 0.2 MW to 3.2 MW.
Implementation Method 1
a first array of heat exchange tubes (93) arranged in a first heat exchanger unit (71a), a second array of heat exchange tubes (93) arranged in a second heat exchanger unit (71b)
Implementation Method 2
a superheater coil (206) arranged between a pair of support elements (211a, b), the superheater coil (206) being formed as a helix
Implementation Method 3
at least one, in this embodiment a plurality of condensers (21) which receive used steam from the steam engine (3), condense the used steam to a saturated liquid
Data Source
Figure 1A
Figure 1B~1C
Figure 2
AI summary
A steam generator for generating a superheated fluid from a working fluid using a stream of heated gas, the steam generator comprising : a housing, which defines a gas flow path having an inlet at one, upstream end thereof into which a stream of heated gas is delivered and an outlet at the other, downstream end thereof; and a steam generation module which is disposed within the gas flow path of the housing, the steam generation module comprising a heat exchanger which receives a working fluid and is operative to raise the temperature of the working fluid to provide a saturated fluid, and a superheater which receives the saturated fluid from the heat exchanger and is operative to raise the temperature of the saturated fluid and provide a supersaturated fluid.